koc-p-001 r2 painting and coating of metal surfaces new construction
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NO
KOC-P-001
KUWAIT
OIL COMPANY
K.S.C.)
STANDA RDS PUBLICATION
KOC
STANDARD
FOR
PAINTING
AND
COATING OF
METAL SURFACES
-
NEW CONSTRUCTION
DO C. N O. KOC-P-001
STANDARDS lVlSlON
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KOC STANDARD
FOR
PAINTING
AND COATING OF
MET L SURFACES NEW CONSTRUCTION
DO C. N O . KOC P 001
ISSUING AUTHORITY:
STANDARDS DIVISION
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TABLE OF CONTENTS
FCrcWORD
S OPE
APPLICATION
TERMINOLOGY
REFERENCE CODES AND STANDARDS
ENVIRONMENTAL CONDITION
HEALTH, SAFEN AND ENVIRONMENT
PAINTS COATING MATERIALS
SURFACE PREPARATION
PAINTICOATING APPLICATION
INSPECTION AND TESTING
QUALITY ASSURANCE
DOCUMENTATION
PAINTINGICOATING SCHEDULES
COLOUR SCHEDULE
APPENDICES
APPENDIX
I : Q A I ~ N G
ECORDDATA
SHEET
APPENDIX
2A
COLOUR SCHEDULE Table
1
APPENDIX 8
:
COLOUR JDENTlFlCAlION FORHAZARDS
AND FIREISAFETY Table 2
APPENDIX
2C
COLOUR IDENTlFlCAT ON OF
GAS
CYLINDERS OR INDUSTRIAL GAS
VIDE
BS 349 Table 3
Page No
6
6
6
8
10
11
13
16
22
27
30
3
31
32
35
36
7
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DOC O.
KOC-P-001
Page
4
of 55
REV.
2
APPENDIX 2 D
APPENDIX 3 A
APPENDIX
30
APPENDIX 3C
APPENDIX
3D
APPENDIX 3E
COLOUR IDENTIFICATION FOR MED ICAL
GA S VIDE
BS 1319 Table 4
SCHEDULE A EXTERNAL PAINTING1
COATING SYSTEMS FOR ONSHORE
STORAGE A N D PROCESSING EQUIPMENT
SCHEDULE B PAINTING SYSTEM S FOR
ONSHORE STRUCTURAL STEEL WOR KS
SCHEDULE C PAINTING SYSTEMS FOR
MECHANICAL, ELECTRICAL AN D
INSTRUMENT ATION EQUIPMENT
SCHEDULE D PAINTING OATING
SYSTEMS FOR OFFSHORE STRUCTU RE
EQUIPMENT (EXTERNAL SURFACES -
ATMOSPHERIC
ZONE,
SPLASH
ZONE
SUB
SCHEDULE
E
NTERNAL PAINTING
SYSTEMS FOR STORAGE AND
PROCESSING EQUIPMENT
S E A
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FOREWORD
This docume nt KOC Standard for Painting and C oating of Me tal Surfaces
-
Ne w
Construction has bee n amended t o incorporate the several changes occurred since
.
its first publication (Rev.1) in 1995 Funher,
it
has been update d in line wrth
Preparation Procedure for Generating KOC Standards Recommended Practices
(KOC-A -001). Thus the docum ent (Rev.1) was superseded and withdrawn .
This revised Standard
(
Rev.2
)
has been approved b y th e Standards Technical
Comm~ttee STC
)
and t he Standards Division for publication wh ich is ult~ ma tely
intended for use throug hout th e corporate engineering and operational fun ct~ on s f
Kuwait Oil Company.
This Standard sets out t o achieve the follow ing objectives:-
6)
To esab ltsh the basic technical requirements for surface preparation, pa int ~n g
maierials, meth ods of application and inspection/testing of protective external
internal coating tpainting of metal surfaces abovegro und in oil, gas and sea
water facilit ies and related utilities under bo th onshore offshore conditions.
b
To provide th e general technical guidance for developing projec t specifications
in order t o achieve reliability, quality and safety in an economical m anner.
C)
T o set our clear requirements t o mon itor compliance in design, material
seiect~ on, pplcation, inspection testing w ith a contract.
d T o maintain the KOC requirements of safety and environmental protectio n
established by UO egulations and procedures.
Feedback as we ll as any c omm ents or suggestions derived fro m the application of th is
Standard
at
any stage of engineering, purchase or field application are invited and
should be directed to:
Supdt. Standards Division
(Chairman, Standards Technical Cornminee)
Engineering G roup,
K.O.C.
P.O.
Box 9758, Ahmad i 610 08
State
of
Kuwait.
The amendment
of
th is Standard is acknowledged t o the Task f o r c e (TF-PC101
comprising of th e follow ing members:-
Mr. S. Kumar - Standards Division
Dr. Muay yad Aj jawi
-
Ex)
Standards Division
-
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SCOPE
This Standard specifies the minimum basic requirements for surface
preparation, coating materials, me thod of application and inspection/testing for
pro tecti ve ex tern al a nd wher e applicable, internal paintinglc oating
of
metallrc
surfaces above ground oil, gas and sea water facilrties and related utilities.
This Standard covers the paintinglcoating for b ot h ne wl y constructed onshore
and offshore facilit ies.
It
also covers the repair o f defects or damages t o the
ne w painted i tems.
The internal linings (Gunite Fibreglass) of tanks and vessels are covered in
separate docu men ts KOC-P-002, Pan s respectively.
Th is Standard is no t applicable t o buried pipelines and subsea lines, decorative
parnts for non-metal surfaces areas (concrete, masonry, w ood , etc .), freld t r ~ a l
of n ew ly developed pa ~ntrng /coating ystems.
APPLICATION
The materials and equipm ent for surface preparation, paint and coating
app lcati on and inspectionltesting, shall con form t o th e requirements of this
Standard and the referenced standardsk odes mentioned herein.
Any except ions or deviations fr om this Standard, along w it h their merits
justif ication, shall be brought t o the attention of KOC's Controll ing Department
for their review , consideration and amendm ent by Standards Division (if
required).
Compliance w ith this Standard does not of i tself confer imm unity fro m legal or
statutory obligations.
TERMINOLOGY
Definit ions
For th e purposes of this Standard, t h e following definitions apply:-
Abrasive
Natur al or sy nthetic solid m aterial used
as
a medium
in
abrasive blast-cleaning.
Grit
te rm used
to
describe
the
angular or irregularly shaped particles o f abrasives
used.
<
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Shot
te rm used t o describe th e spherically shaped panicles
of
abrasive used for
blast cleaning.
Comparator
A
specimen surface, or surfaces,
of
known average profile, representing a
panicular abrasive blast-cleaning process.
Coat
A
continuous layer
of
a coating material that results fr om a single application.
Cure
The chemical reaction resulting in the fina l polymerized produc t in the
psin1 coa;~ng
system.
Discontinuity
(Holiday
void, crack, thin spot, foreign inclusion or contamination in the coating film
that significantly lowers the dielectric streng th of the coating.
ry Film
Thickness
The
dry
film
thickness of paint is the thickness of p aint wit hou t solvent and is
measured by f i lm thickness gauge expressed in micr on
(10 00 microns
equivalent to 1mm .
Pot life
The elapsed t ime with in which
a
coating can be effectively applied after all
components of coating system have been thoroughly m ixed.
Rust
grade
degree of rusting)
Classification describing t he degree of
rust
formation
on
a
steel surface prior t o
cleaning.
Atmospheric Zone
Th e par t o f an offshore structure above th e splash tone .
Splash Zone
The zone of the structure that is sfternately
in
and out of th e water because of
th e
influence of
the
astronomical tides, w inds an d
sea
waves.
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DOC
O.
KOC P 001 Page 8 of
55
REV
2
Submerged zone
The zone that extends downward from the splash zone and include that
structure below the mudline.
Surface Rofile
he micro-roughnessof a surface, generally expressed as the average height of
ye major peaks relative to the major valleys.
Abbreviations
KOC Kuwait Oil Company K.S.C.)
CS Carbon Steel
DFT
Dry Film Thickness of Paint)
WFT Wet Film Thickness of Paint)
M
0 Micaceous Iron Oxide
RH Relative Humidity
LAT Lowest Astronomical Tide
REFEREN E
CODES AND STANDARDS
Conflicts
In the event of conflict between this Standard and the standardskodes
referenced herein, or other contractual or purchase requirements, the most
stringent requirement shall apply, unless otherwise specified.
List of Standards, Codes
and
Specifications
The latest edition of the following standards, codes and specifications shall
apply
National International Standards
Paintin~Coat ing General
BS 49
Identification of the Contents of Industrial Gas Containers.
BS 381C
Specification for
olour
for Identification, Coding and Special
.
Purposes.
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D O C . N O . K O C P 0 0 1
Page 9
of
REV 2
Specification for Hot-dip Galvanized Coatings on lron
a n d
Steel
Amcles.
Specifcation for Identification of P~ pel lnes nd Servic es.
Specification fo r Bitumen-based Coating s for Cold Appl~c atron,
Suitable for se in Contact with Potable Water.
Sch edu le of Paint Colours for Buildmg Pu rpo ses.
Code of Practice for Protective Coating on lron and Steel
Structures agarnst Corrosion.
Metallic and Other Inorganic Coatings. Therm al Spraying, Zrnc,
Alumrnum and their Alloys.
Surface reparation
--
AS TM
D2092
G u ~ d e fo r Treatment of Zmc-Coated Galv an~z edi Steel
Surfac es for Painting.
ES 7079 -A1
Spe cifc atio n for Rust Grades and Preparation Grades of
I S 3
8521- 1 Uncoated Steel Sub stra te and of Steel Sub stra te After Overall
Removal of Previous Coatin gs
-
Visual Assessment of Surface
Cleanllness.
ES 7079 D2
Preparation of Steel Substr ate Before Application of Paints and
IS0
8504-2
Related Produ cts. Abrasive Blast Clean ing.
SIS 05 59 00 Pictorial Sur fac e P reparation St an da rd s for Painting Steel
Surfaces .
SSPC-SP Steel Structu res Painting Council S ur fac e Preparation
Specifications.
Inspection nes tin g
ASTM Dl
186
Test Method for Nondestructive Measurement
of
Dry Film
Thickness of Nonmagnetic C oating s Applied to a Ferrous Base.
ASTM Dl212 Test Methods for Measurement
of
Wet Film Thickness of
Organic Coatings.
ASTM D2697 Test Method for Volume of Nonvolatile Matter in Clear or
Pigmented Coatings.
ASTM D3276
Guide for Painting Inspectors Metal Sub stra tes) .
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AST M D3 35 9 Test Methods for Measuring Adhesion by Tape Test.
ASTM DUl7 Te st M etho ds for Field Measurements of Surface Pro f~le f
Blast Cleaned Steel.
ASTM D4541
Te st M eth od for Pull-Off Streng th of Coatings Using Portable
Adhesion-Testers.
BS
3 9 0 0
H3
Designation of Degree of R usting.
I S 0 9000 Mo del of Quality Assurance in Design, Development,
Production, Installation and Servicing.
NACE
RP 188
Disco ntinuity Holiday) Testing of Protective Coatings.
A C E R23287 Surface Profile Mea surem ents of Abrasive Blast Cleaned Steel
Surface Using a Replica Tape.
SSPC
PA 2 Measurem ent of Dry Paint Thickness w it h Mag netic Gauges.
Health and Safety
API 2217
Guidelines for Confined Space Work in the Petroleum Industry.
BS
1 3 1 9 Specification for Med ical Gas Cylinders, Valves and Yoke
Connections.
BS 5378
Safety Signs and Colours.
NFPA 231 Standard for General Storage
OSHA 29 CFR 191 Regulation, Penaining Wor k
in
Confin ed Areas.
KOC Standards
KOC Fire and Safety Regulations.
KOC-GO02
KOC Standard for Hazardous Area C lassification.
KOC-G-007
KOC Standard for Basic Des ign
Data
ENVIRONMENT L CONDITION
T h e e n v i r o n m e ~ tof Kuwait, is severe
o
all plant and equipment and must be
considered carefully before selection/approval o f paint s an d coating materials.
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The ambient temperature range is - 3°C t o 55°C. The expose d black body
metal temperature d ue t o solar radiation is 85T
Humidi ty can pose a serious problem with long periods of relat ive h u m ~ d ~ t y
(RH)
level of
100
being p a n of normal weather pattern.
other environmen tal conditions in Ku wa it, refer t o KOC Standard for Basic
3esiyn Data, KOC-G-007, w hich provides the detailed design inform at~ on
,.?garding the environm ental, site and util ity supply conditions prevailing
i rough out
the KOC facilities.
HEALTH, SAFETY AND ENVIRONMENT
General
The contractor shall employ all necessary health and safety procedgres to
pro;ect pe rso me and surrounding environment during on-site f~ e ld orks .
Ali r ~ i e v a n ts ~ f e t y equirements of the KOC Fire and Safety Regulations shall
be conformed, in part icular the requirements for blast ing and power tool
cleaning, for scaffolding and access platforms, for compressors and
compressed air equipment for ve ntilation and ventilation equipm ent in confined.
areas and for personnel protection, p rotectiv e equipment and clo thing.
The contractor shall com ply wi th the KOC Fire
&
Safety Regulations and the
Health & Hygiene Procedures while performing the works within KOC areas.
Where there 1s
a
risk of flammable atmosphere being present in a particular
vbiork area, KOC may, wi th relevant safety authority, impose restr~ ct ions n
methods
of surface preparation. Flame heating equipm ent shall no t be used in
hazardous areas. KOC-G-002 describes area class if~cation or faci l~ttes nd
eq i l~pment .
For internal paint ingkoating of drinking water facilities (tanks, vessels, etc.),
the contractor shall submit evidence
(
Kuw ait heath authority approval) tha t
the pa int system wi l l not in any w ay contaminate the w ater.
Storage, Hand ling and M ixing Safety Precautions
Safe Storage
a
All
paints, coatings and thinne rs shall be stored
in
enclosed storage
ereas
or structures that re well-ventilated nd protected f rom
temperatures exceeding manufacturer's recommendations, open flames,
electrical discharge an d direc t sunlight. A ir con ditioned storage areas
shalt be considered where excessive ambient temperatures are expected .
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b )
The storage area shall be secluded and no other materials shall be stored
in the enclosed place. The enclosure shall be demarcated
as O
SMOKING
area strict ly.
C)
Al l paints, coatings, solven ts, o il and equipm ent cleaners shall be s;ored
in closed labelled original containers.
d
Portable fire extinguishers of suitable quality and appropriate.quantlty
shall be prov ided at the storage areas and such extingu ishers shall be
inspected and approved b y Fire & Safety Depanment.
Manufacturer's HealthISafety Precautions
Manufacturer's hea lthha fety precautions and procedures for m ixing, handlrng,
storage and application of paints and coating materials shall be strictly
adhered. Safety precautions shall be clearly described on the technical data
sheet of pamt and coatrng materials supplied as well as on the containers.
Safety Precautions for Blasting Painting Equipment
Blast cleaning and spray painting guns shall be earthed (spark proofm g) t o
prevent building up of an electros tatic charge, especially whe n the application
is in confined w ork places.
All blasting equipment shall be inspected and certified b y an authorised
com peten t thir d pa rty. Pressurised hoses shall be tes ted and certified for
ma xlm um safe work ing pressure. Hoses and other pressure items shall be
checked period~ cally o m ake sure that any damage or loss of electrical
cond uctivity will no t lead t o a safety hazard.
Pressurised hose and blasting gun shall compulsorily be equipped w ~ t h
'Deadman Sw itch'.
Suitable fire extinguishers shall be p rovided near the air compressor.
Enclosures shall be provided all around the area, wh ere shot / grit blasting will
be carried out.
4
Clean sir-mask PPE shall
be
worn b y th e technicians while blasting or spray
painting.
Safety Precautions i n F bm mab le Atmos@wres
KOC
will
advise o n the area classification for b o t h plant design and
construction / maintenance projects. Ce nain paint compo sitions shall no t be
use d i n some plant design area classification
e.g.
zon I , s t can ignite with
explosive force at certain conditions.(see clause 7 1
5
of this Standard).
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The contra ctor shall provide KOC w it h all necessary material safety data sheet
for the proposed paint systems, solvents and painting procedure In order t o
determine area clas sifcation for the duration of painting work .
Safety
Precautions
in
Confined
Space
All tank
/
vessel interiors shall be gas-free. Approval under entry permit
procedure
is
required before the tanklvessel can be entered.
A I elecrrical equipment used including lighting equip men t, v en tila t~o n
equipment, high voltage holiday testing equipment, etc., shall be grounded and
suitable for the hazardous area classifca tion of the wor king areas as advised
b y
KOC.
All other equipm ent includin g ladders, tools, etc., shall be spark-
proof.
The procedures for perform ing safe wor k in confined spaces shall be in
2 -cordance
~ w t h S H A 29 CFR
9
r API 2217
Site Clearance
&
Environmental Protection
On com pletion of painting works, facilities shall be arranged b y contractor for
effective
and safe removal of spillage collection and disposal of pain tsko atin g
materials, brushes, scaffolding, waste, equipment, etc. All necessary
p r e c a i l t ~ o wshall be taken t o safeguard the surrounding enviro nme nt.
PAINTS
OATING
MATERIALS
General
All palnts oating materials shall
be chemically pure, and free fr om foreign
contaminants. The age of coating material components shall no t exceed the
recomm ended pot-life as limited by the m anufacturers.
All paints coating materials shall be delivered t o th e site
in
original sealed
manufacturer's containers w ith batc hk od e numbers and date of manufacture
clearly marked thereon.
pprovals
Al l paints and coating materials, including thinners and equipm ent cleaners, i n
any one sys tem shall originate fr om one manufacturer.
The KOC approved schemes are
only
those used
in
the paintinglcoating
schedules
A E (Appendix
3
end as defined
in c lauses 7.3 7.14 of
this
Standard. The us e of alternative schemes shall be approved i n writin g b y KOC.
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The contractor s subm ittal for paintingkoating materials shall include details of
generalized composition, service temperature and technical specifica t~ons of
the products to be used for KOC review and approval.
The selected composition of painting / coating materials shall comply with the
relevant clauses penaining t o the materials given be low.
inc-Rich Epoxy Rimer
his primer based on polyamide cured 2 pack epoxy. Minimum volume of
solids shall be 63 as per
ASTM
D2697.
Inorganic Zinc Silicate Primer
Sased on ethy l silicate media. Minim um volume of solids shall be at least
589
s per ASTM D2 697 . Capable of withs tanding continuous high temperature
u p t o 403 C) and have excellent abrasion and chemical resistance.
Zinc Phosphate Primer
Based on long oil alkyd and urethane alkyd media. Minimum volume of solrds
shall be 48 as per
ASTM
D2697.
Mordent S olution (1-w ash ) Pre-treatment Primer
Used for preparation
of galvanized surfaces.
t
is a tw o components etch
primer, based on phosphoric acid solution incorporating copper salts and
corrosion inh~b itive igments in
a
solventlwater solution.
High Build Epoxy Intermediate
Based on polyamide cured tw o pack high build epoxy binder. Pigmented with
M~ caceous ron Oxide
(MIO).
Min imum volume solids shall be 55 per
ASTM
D2697.
Coal Tar Epoxy Rimer/lntermediate/Finish
The formulation of the tw o pack incorporate:
Pack
1.
Epoxy resin and suitable pigments.
Pack 2. Polyamide or amine curing agent and coal tar.
The
Epoxy tesin shall comprise at
(east 35
by weight
in
the resin/coal
t a r
blend as per
ASTM
02697
For contrasting of intermediate coats, a luminium or red oxide may be used.
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Two Pack Polyurethane Finish
B2sed on acrylic modif ied t w o pack al iphatic polyurethane wit h t i taqium
dioxide or M I 0 pigment.
Minimum volume of solids shall be 45 per
ASTM
D2697.
se vi-g los s and colour retention f inish is required.
;mine Adduct Epoxy Paint
4 t w o pack epoxy amine adduct cured paint wh ich cures to a coating wi th
excellent resistance to chemicals.
Mm imum volume of sol ids shall be
48
as per
ASTM
D2697.
IT shail be approved by the N I Y C (Na tional Wa ter Counc il) and Kuiv ait heal:?
a ~ t h o r i t y .
Solvent Free
High
Build
Epoxy
Paint
f32sed
on
polyamide cured t w o pack epoxy wit h a coat ing w i th good
resistance t o fresh water and t o abrasion.
Minimum volume of solids shall be
100
per ASTM
D2697
(solvent free).
It shall e approved b y the NWC (National Water Counc il) and health au thority.
Zinc
Free
Inorganic Silicate Finish
Air curing zinc free inorganic sil~ ca te ased on eth yl sil icate media; capable of
wrthstandmg continuous
high
temperature (up t o 400'C) and have excellent
abrasion and chem ical resistance.
High Temperature Alum inum Silicone
Finish
Based o n si l icone alkyd or modif ied sil icone alkyd media
e.g.
ecrylic sil icone).
M ~ n i m u m o lu me of sohds sha ll be 49 as per ASTM 02697.
Ptgmtrnted w ith leafing aluminium pigment.
Heat resistant, capable t o withstand continuous high temperature up t o
400°C.
M us t be capable
of
curing t o handle at ambient temperature.
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Me tal Spray Coatings
a) Based o n mo lten Alum inium me tal sprayed o n surfaces prepared in
accordance w ith BS
EN
22063.
b ) Aluminium me tal spray coating is suitable fo r high temperature (up to
550°C) surfaces with restriction (see clause 7 15) . The sprayed
aluminium may be silicon sealed and for temperatures up to 250'C silrcon
sealed sprayed aluminium can provide more protection and longer I~ f e .
Restriction
on
Using
Aluminium
Pigments and M eta l Spray
Due t o the susceptibil i ty of metall ic aluminium to ignite wi th explosive force,
Alum inium metallic pigments and Aluminium metal spray shall no t be used on
any
surface operating above
1 2 0 T
in area tolie
1
as specified in KOC
Standard for "Hazardous Area Classification"
(KOC-G-002)
or
KOC
Hazardous
Area draw ings.
SURFACE PREPARATION
General
All fabrication wo rks including cutting and drilling of holes shall be completed
prior t o surface preparation. In special areas, how eve r, preparation and
priming
of s tructured steel members and piping ma y be approved
b y KOC
prior
to f inal assembly.
Surface preparation shall preferably, for optim um c oating performance, be
carried ou
by
dry abrasive blast cleaning. Alternative techniques shall only be
applied in some circum stances as described in clause
8 7
The surface preparation requirements for p ainting system s are indicated in the
painting schedules
A-E
(Appendix
3)
and detailed in the clauses as follows:
Working Restrictions
Weather Conditions
All surface preparation shall not be condu cted
in
the following conditions:
a)
W hen th e steel surface temperature is less tha n 3 above de w point .
0
W he n the air temperature
is
below
5°C
C)
Wh en the relative hum idity
RH)
s 85
r
higher.
d
Under adverse weather conditions, e.g. rain,
fog,
sandstorm, high wind
velocity (56 K m h r. or higher) , high wave t ide or whe n such conditions
are l ikely prior to completion of the work i e abrasive blast cleaning
1
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8.2.2
Work Cond~t ions
F~ el d urface preparation shall not be conducted in the following co nd ~ t~ on s:
Outside daylight hours on exterior locations, unless permitted by KOC.
Approved special lighting shall be arranged for night blast cleaning.
W he n the initial primer coe? cannot be completed w ith in 4 hours of
prepara:ion. Surfaces wh ich remain unco ated for longer th an this period
shall be reblasted prior to priming.
When
adjacent
areas
or equipment are insufficiently protected from
damage or contamination b y abrasive dust or debris.
In areas close to painting operations, t o prevent damage or contam ination
of we t palnt films b y abrasive material.
8 3 Surface Imperfections Removal
Surface impe rfections or irregularities shall be removed completely (made flush
or sm oo th) prior t o blast cleaning. Imperfections shall be considered as
fol lows:
LVel
spatter and slivers shall be removed. Sharp or rough welds shall be
rounded and contoured. Any other observed defects in welds and
material should be referred to KOC for dispos it~on.
Po ro s~ ty (w eld voids) shall be cleaned and fil led w it h acceptable fil ler
mz?erial or closed over b y a suitable mechanical meth od approved by
KOC.
Sharp or rough edges shall be rounded, chamfered or broken.
Such impe rfections tha t appear after blast cleaning or acid pickling shall
be similarly removed.
If
grinding is needed, check ing of the remaining
wa ll thicknes s and KOC s approval are required.
8 4
Surface Contaminants Removal
8 4 1
The me tal surface shall be cleaned t o remove any
oil
grease,
din
etc. using
solvent andlor suitable emulsifying alkaline cleaners fol low ed by washing wi th
clean water
or
w et steam r insing.
SSPC SP7
outlines these m ethods.
8 4 2
Degreasing by wiping the surface with solvent only is not recommended in
heav ily oillgrease surfac e contamination, because thi s invariably leads t o the
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DOC. NO. KOC P 001 Page 18 of 55
I REV.
2
spreading of a th in film of oil over wide area. The solvent/emulsifying agent
cleaned surface shall be allowed t o dry before proceedmg w ith further
preparation or painting.
Soluble salts on steel surface exposed t o a salt laden atmosphere shall be
removed by washing or
by any other suitable techn ique. See clause
10.5.3
for iron salts contaminant free testing.
Dry Abrasive B last Cleaning Practice
Dry abrasive blast cleaning shall be used t o remove all rust and mill scale and
t o achieve th e required visual standard and surface pro file defined in the
approved painting'coating schedules (Appendix
3).
Ab:ssive material shali satisfy the follow ing requirements:-
Abrasive material for mild
/
carbon steel preparation shall be indu str~ al
grade metal angular grit or shot (generally iron or steel). Contaminated or
re-cyc led grit or s hot shall no t be used. Abrasives for stainless steel
substrate shall be non-metallic materials. New less-dust generating
abrasive media suc h as Garnet plastic granulates and alike, capable of
produc ing the required surface profile, m ay be used for blast cleaning.
Sand m ay be used as abrasive material for field blast cleaning, subjec ted
t o KOC's approval. Sand material shall be graded
30
6 0 mesh), hard,
version, si lca or olivine sand w ith less tha n a 10 percent breakdown. No
sand shall be used more tha n once.
The selected abrasive material shall be in accordance w ith SSPC-SP-COM
or BS 7079 R IS0 8504-2 .
Abrasive material shall be dry and free fro m oil, grease, dust, salts and
any other impurities or contaminants.
Abrasive materials shall be capable of achieving th e required surface
profile with out contamination of the substrate. T o produce th e required
surface profile, abrasive particle size shall fol low th e surface preparation
commentary of SSPC manual as necessary t o comply w ith visual blast
cleaning standards mentioned in clause 8.6 of this Standard.
All abrasive materials shall be
kept
dry,
nd
covered wh en no t used.
Abrasive material sample shall e provided
by
th e contractor, for KOC's
testing a nd approval before wo rk comm encement.
Th e blasting equipment and technique shall comply wit h the fol lowing
requirements:
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The con trac tor's abrasive blast cleaning equipm ent shall sat isfy KOC's
safety requirements (See clause 6.3 .
For field and shop blast cleaning, abrasive shall be carried by a jet of
compressed air through a hand-held nozzle. The compressed air s u ~ p l y
and
volum e shall meet wo rk requirement and shall be substantially free
fr om oil and wa:er contam ination. Traps and filters shall be cleaned
regularly.
For blast cleaning of large horizontal surface areas,
like tank roofs ,:
bottoms etc.,
a
self contained v acuum blast unit can be used. Sirch
machines are usually operated by remote compressed air or hydraulica ly
actuated for tractio n.
'Deadman handles' shall be fixe d t o th e blast line as close as practicable
to t h ~last nszzle and shall be held b y the blast operator alone.
Nrjzzles used shall have a ma xim um oriflce size of
9
m m and shall be of
ventur l des~g n.
Openings in vessels, piping, access fitting s, nozzles, et c. shall be properly
protecte d against entry of abrasive material. All previously painted or
ga ~,anisedsurfaces shall be adequately protec ted prior t o comm encine any
blasting operation.
Giast cleaned rus ty surface (due t o rain or condensation) and surfaces w ith
temp orary holding primer, shall be re-blasted t o the specified surface profile.
Surface blast cleaning t o the specified surface profile shall exte nd
a
min imum
of 1 5 0 eyond the area to be coated during the same day.
Surface blasting t o the specifled surface profile shall continu e a minim um of
25 m m into adjoining previously coated surface. Th e edges of the previous
coating shall be feathered.
All prepared surfaces shall
be
cleaned from any dust / abrasive material
preferably by dry brushing andlor vacuuming wi th industrial vacuu m cleaner.
Pressure air blowin g is no t permitted. A ny surface sho win g signs of
contamination, after blast cleaning, shall be solvent cleaned and re-blasted.
Blast Cleaning Standard
The surface profi le height shall be
in
accordance w it h th e requirement of
painting system. The measurement techniques
of
surface profile testing are
specified in
ASTM
D4417
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DOC.NO.KOC P 001
P a ~ e
0
of 55
REV 2
Blast cleaqing shall be carried out t o a visual standard in accordance
w t h S S
05 59 00 e~ther
s Sa
2,
Sa
2 /1
or Sa
3
(identical
to BS 7079
Part
A1
or IS0
8501-1) subjected to the requirements of paint manufacturer's data sheet.
Reference shall be made t o th es e standards for photographs of equivalents to
th e mentioned qualities.
Gestrictions on Atterna tive Techniques t o Blast Cleaning
so me circu mst ance s, blast cleaning shall not be done and alternative surfac e
.reparation techniques like manual power tool cleaning shall be applied.
Th ese alternative techn ique s are subjected to KOC's approval and restricted a s
iollows:
a
When
dry
abrasive blast cleaning
is
unsafe
or
any of KOC's safety
precautions / requirements cannot be met.
b
When there
is
a
risk
of dam age t o instrumentation, equipment (e .g .,
electrical, rotating, etc .) within the proximity of blasting operations.
c) Where there is a flammable a tm osp her e or similar condition present,
restrictions may be applred by KOC.
d ) Where blast cleaning is not practical, e .g . for welds, ed ges , bolts, nuts,
corne rs, crevices et c. and for paint d efe cts tda ma ges repair.
Power Tool Cleaning
Power tool cleaning shall be to
a
visual standard in accordance with SIS 05
59
00 St3
or
BS 7079 Part A1 S t 3 (equivalent t o U.S. Standard SSPC-Sp 3).
Where power tool cieaning is carried out, 100 of the surfac e shall be
covered using abrasive or wire typ e power discs. In so m e locations which can
not accommodate a power disk, e.g. welds, pow er impact tool s shall be
applied (vibratory a n d rotary, needle gun s, scrape rs) followed u p by wire brush
cleaning.
Pow er tool cleaning shall exte nd a minimum
of 25
mm distance into adjoining
coated surfaces.
Hand
Tool
Cleaning
Hand tool cleaning ma y be used for cleaning rusted surfac es n s o m e
circumstances s specified
n
clause 8.7 an d for paint d efect sJdam ages repair.
Hand tool cleaning shall be
to
visual stan dard in accordan ce with S IS
05 59 00
S t 2 (BS
079
St2 ) which is equivalent to SSPC-SPZ..
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Acid
Pickling (Etching) Prepara tion
This method may be used by contractors, in so me circumstances and locattons
a s a n alternative to blasting provided tha t
it is
compatible
with
palnt sys tem
and approved
b y
KOC
When using t h i s
method,
the
surface shall be etch ed t o a d egre e suitable for
th e specified coating syst em . Details on this method are specified in SSPC-
SPB.
KOC
Flre and Saf ety Regulations shall
be
adhered t o when using
this
method
Preparation of Stainless Stee ls
Sramless stee ls shall not b e painted unles s specifled by th e relevant equipm ent
d : ~
7 e e t . he s urfs ce specifled t o be painted shall
be:
th0:oughly deg re ase d using solvent cleaning or suitable emu lsif y~n g ae nt
and washed with fresh water t o remove a ny contamination.
blast cleaned to a surface profile
of 25-50
micron using chlorlde
free
abrasive su ch a s alumina. Copper slag abrasiv es shall not
be
used . Hand
or
power tools using
P6
grade paper may
be
used for surface
preparmon, when grit blast cleaning is impractical. (s ee clause
8.7).
protecte d from an y fu nhe r contamination by debris produce d during grit
blas?ing of adja cent carb on steel because embedded panicles could
promote corrosion. Any observed contamination should
be
referred to
KOC
for disposition.
Blast
/
Power tool cleaning equipment used for carbon steel
shall not
be
subsequently used on stainless steel.
Preparation of Galvanized urfaces
Painting of new galvanized surfaces shall be only for top coating purpose in
conformity with systems
B1
Dl -1
0
l 11 of Appendix 3 of th i s Standard.
The
surf ace preparation metho d shall
be
carried out as follows:
a)
The g reasy
film on t h e ne w galvanized steel surface and a ny other
oil
or
grease contamination shall
be
removed using emulsifying agent:
b
The surface
shall be
chemically e tc he d (primed) by using proprietary
T
wash solution.
see
clause
7.6
C
Weathe red surf aces shall be cleaned using wire brushing or s w e e p
blasted
to
rem ove all corrosion produ cts
or
deposi ts and degreased wrth
emulsifying agent.
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8 . 1 2 . 2
Other su rfa ce preparation me tho ds may be used in acc ord anc e with ASTM
D 2 92
for painting ne w galvanized sur fac es subject t o KOC s approval.
PAINT/COATING APPLICATION
General Requirements
Paintingkoating works shall be in accordance with
the r quir m nts
established by t h i s Standard and t h e recommenda tions of th e paintlcoatlng
manuf acture r. Any are a not specifically cove red, shall be in accord anc e wrth
th e principles and guidelines set fonh in the SSPC Manual.
Th e c ontrac tor shall provide all materials, tools, equipmen t and manp ower
required for carrying out the works.
Surfaces , to
be
painted /c o at ed , shall be inspected and approved
b y KOC
before any pa~n tlng oatmg
is
applred. Thrs shall be after surface preparation
and between each subsequent coating. No primer or paint shall be applled
v,~~thoutOC s approval.
All
sur fac es, t o be painted coated , shall be d ry and dust contaminants free
before applcatlon of th e first coat.
Precautions
shall be taken t o prevent painting from being ap pl ~e d o name
plates, cou pl~ ngs , hafts, valve stems , vent openings, gauge glasses, pressure
ga dg es , et c. Masking ta pe , plastic film or any other suitable material shall be
used, and all shall be removed after completion and acceptance of the palntlng
apphcatron.
All
area s prepared for field welds shall be kept free from paint over a drstance
of at least
1
mm from th e weld cen tre, ex cept welding sho p primer of 25
mrcrons.
A
minimum
of
1 mm around ed ge s
of
abrasive blasting shall
be
left unless
adjoining
a
recently prepared a nd coated other surfac e.
Crevices created
y
t w o surfaces in close contact which cannot
be
protected
by
painting should
be
mastic sealed on both sides.
Selection of
paint in^
Coating ystem
The selection
of
painting coating sy st em for particular applications and
required su rf ac e preparation Shall be as given
in
t h e approved painting
Schedules A
B,
C
D,
and (Appendix
3
of
this Standard.
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DOC. NO KOCP 001
REV. 2
Paint Mixing and Thinning
Mlxin g of paint t o an even consistency, manufacturer s mixing instruc t~ons ,
environme ntal conditions and ma ximu m pot l ife shall be strictly adhered,
special ly for T w o pack paints.
Mixing,
by h h speed mech anical agitators or rotary mixe rs, w it h flat blade
?nd speed control, shall
be
used for containers larger th an
5
I~ t res . and
71xrng is perm rned o nly for containers
u
to l i tres.
t o r paintin g systems where pigment separation readily occur e.g . zinc sil icate
~ ri m e r s , ontinuous mixing shall be carried out during appl ication.
After tho rou gh mixing, the correct viscosity of th e paint shall be proved by
measuring with an approved f l ow cup.
Thinners shall not be added to p aint witho ut KOC s approval, only the thlnners
recommended b y the palnt manufacturer may be used, even for cleanrng.
When
thinning is permitted by
KOC,
paint manufacturer s instructions shall be
strictly adhered and the accepted procedures mentioned in clause 7 3 of
ASTM
D3276
shall be fol lowe d.
Restrictions
on
Painting
Weather
Conditions
Palnting shall no t be cond ucte d in the similar weather conditions of abrasive
blast cleaning as specified in clause 8 2 1 of this Standard and also under the
fo l lowing c ond i t~ons:
a
Wh en the metal surface temperature above
50°C
b) Under adverse weather condit ions, e.g. rain, fog, sandstorm, high win d
velocity
(56
Kmlhr. or h igher), h igh wave t ide or whe n such cond i t~ons
are l ike ly before the paintk oat ing has become dry.
Work Condit ions
Painting Coating shall not be conducted in the fo l lowing work condit ions:
a)
Whe re t h e specif ied surface f inish is not existed t th e t ime of apply ing
th e fi rst coat.
b
W he n adjacent areas or e quipment are no t suff iciently protected fr om
paint appl ication.
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DOC NO .
KOC-P-001
Page 24 of 55 REV. 2
C )
Outside daylight hours on exterior locations, unles s permitted
by
KOC
Approved special lighting shall be arranged for night painting.
9 5 Paint Application Practice
9.5.1 General
The specified surface fmisfi, of all areas t o
be
painted, shall be prepared
before applying th e first co a t ff required, su rfa ce s shall be re-prepared t o
the specifled fmish.
The paint shall be applied in a uniform manner a nd to the prescribed
number of coa ts and
dry
film thicknes s DfT)given in Painting Schedules
without any .runs, sags ,
marks or other blemishes. Finished application
shall be uniform
in
colour, texture and appearance.
Intermedia te and finish paintings shall be applied following final assembly
of component pans. For surfaces inaccessible
for
proper painting and / or
inspection, painting shall be applied prior t o final asse mbly . The
contractor and KOC will designate inaccessible areas.
Where a multi-coat paint sy stem is specified to
be
us ed , all intermediate
co at s shall be of contrasting colour t o differentiate betw een coat s.
Colours for intermed~atecoats shall refer t o th e paint manufacturer s
recommendations.
T m e intervals between coat s shall be kept t o
t h e
minimum recommended
by pamt manufacturer in order to prevent contamination between coat s.
In case
contamination does occur, it shall be removed by washing w~tti
suitable dete rge nt solution and rinsing with clean
fresh
water.
9.5.2 Airless Spray Application
a)
Paint application by airless spraying shall be the preferred paint
application process. The use of air spra y method shall conform to t h e
requirement
of
coating sys tem and shall
be
subject
to
K Cts
approval.
b)
Spraying equipment, guns, nozzle size s, orifice sizes shape s and
pres sure range s sP.ali me et t h e work requirement s an d t h e paint
manufacture r s recornmendations an d shall
be
free from
oil
and water
contamination.
C
All
paint spraying lines and pots
shall
be cleaned a nd flushed before the
addition o new material.
d
Large surfaces shall be painted with passes
in
t w o directions a t right
angles. Spray overlap of th e previous pa ss shall
be
by 50 . .
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9 5 3 Brush Application
Brush applicat ion shall be done on areas which cannot be properly
sprayed
e.g. for welds, edges, bolts, nuts, corners, crevices etc., and for
tou ch -up maintenance where spray application is no t pract ical.
Stripe coating of sharp edges, corners and welds ca n be done before
application of f lnish paint t o ensure that these areas receive the mln lmJm
specifred fi lm thickne ss.
Brushes shall be of a type, size and shape which permits proper
application of paint and meets manufacturer s recommendations.
Brush application shall be done such that a uniform coat, w ith no deep or
de tr~m en tal rush marks, is obtained. Runs and sags shall be avo ~d ed .
T h ~ s method of applcat ion can be used, subject to KOC s approval, for
painting large areas of relatively flat steel surfaces a nd w here high fi lm build is
generally no t t o be attained. Roller application wil l ride over high spots and
mlss edges and shall not
be used for pa inting corners, bolt heads, etc . Care
mi ls?
e
taken
t o choos e the correct roller pile length, depending o n the ty pe
of paint and degree of roughness of the surface.
9.6
PI
iming
9 6 1 Priming shall be done on prepared surfaces before rusting occ urs or wit hin
4
hours of blast cleaning, whichev er is sooner. The only relaxation allowable t o
this requirement is where the following three 3)conditions are existing.
a)
The wor k t o be primed is ful ly enclosed.
b )
The ambient temperature
is
above
1
I°C
C
The relat ive hum idi ty is be low 75 .
9.6.2
All acid descaled steel surfaces shall be primed as so on as the surface is dry
and w hi le it is still warm.
9.6.3
In order t o faci l i tate shop or site handling procedure, holding (shop) primer of
25 microns may e applied on stee l surface.
f
pplied, however, this shall not
replace the funct ion
or
pan of the f i lm thickness specif ied for th e priming coat.
Shop or we lding primers shall
be
compatible with the specif ied paint ing
system.
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DOC
NO.
KOC-P-001 P a ~ e
6 of
55
REV.
Zmc silicate primers shall be applied to abrasive blasted surfaces on ly. In order
t o protect the porous primer fi lm fro m salt or chemical contamination,
rt
shall
be sealed
w ith a tie coat as soon as practicable after complete curing has
occurred. The tie coat shall achieve sound adhesion t o the zinc siicate primer
and be compatible w ith the finishing co at.
hop
Painting
3 0 p painting of i tems may be carried out b y the contractor as below, subject
KOC's approval.
3
The contractor shall be responsible for paint condition on arrival of such
items 'on -site' and shall carry out any paint damage repair needed.
b
The contractor shall com ply with all aspects of this Standard and related
aspects of KOC's safety regulations.
Completely Fabricated Items
a Full surface preparation and painting wo rks shall be done prior t o
transportation t o site.
b
All painted items shall be protected packed t o avoid any coating damage
during transpo rtation. Care shall be taken in handling and insta llat~ono
minimize coa ting damage.
Partially Fabricated or Non-Fabricated ltems
a These items ma y be prepared / primed and further coated before
transportation to sire wi th the approval of KOC.
b
The painting used shall have enough durability t o withsta nd the 'on-site'
constru ction period before further painting occurs.
Repair
of
Darnages'Defects
New painted surfaces are likely to require repair and maintenance in the
following cases:
a
f o r painted areas wh ich have been damaged b y other adjacent f ield
activities or during handlingltransportation of off-site painted items.
b
For areas wh ich suffer pain t defe cts
e.g.
disbonding, insufficient fi lm
thickness, blisterin& etc.
The t yp e of coating materials used for repair and maintenance shall be identical
to, r compatible w it h the original material.
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The selection of suitable surfac e prsparation shall dep end on the size of areas
t o be painted, th e type of repair painting materials t o be
used
and the Safety
regulations involved. Th e following order of pre fere nce shall be adopted.
a )
Dry blast cleaning t o t h e required visual standard
(
S a 2 or Sa 3 and
su rf ac e profile.
2
Power tool cleaning ro standard
St3
(only wh er e blast cleaning
is
not
practical or permitted).
Hand tool cleaning t o standard
St2
(only for minor touch up repair
work)
Surf ace preparation of defective or dam aged ar eas shall be extende d over the
surroun ding so un d coating for a minimum of 25 m m on all
sides
and a further
25 mm
of sound paint
work
shall be lightly blasted t o et ch t h e surface.
Surfaces to be painted that beco me contaminated with oil, grea se, salts , et c.
sh ll
be cleaned with a proprietary solvent ideterg ent solution and
rinsed ~ ~ 2 1 t h
fres h clean water .
Repair works shall be in acc orda nce with t he specified painting sys tem t o
res tore the f~ lmhicknes s and shall cover the prepared surf ace and the etched
p a n t work For colour codmg and /or cosmetic reas ons it may
be
necessary to
extend th e f ~ n ~ s hoat over a large surrounding area .
It
is
mandatory thai all defective work
be
corrected to
the
sat isfa ctio n of
KOC s
represen tative. Work shall not
be
dee me d comple te until the foregoing
bas been achieved.
INSPECTION ND
TESTING
General Requirements
lnspectlon and testing at all sta ges of surfac e preparation and paintingkoating
a p p l c a t ~ o nshall be conducted
by
the contractor. T he contrac tor shall provide
all nece ssar y inspection equipme nt and perform su ch inspections as necessary
t o assu re th at th e painting coating complies with the requirements of this
Standard.
Surface preparation and painting /coa ting application m a y be subjected to
inspection an d approval at any s tag e by KOC.
KO
inspector shall have th e right to inspect at all times an y tools, materials or
equipment used in the performance
of
surface preparation
nd
paint
application
to
ensure
t h e
compliance with th e requirements
of
this Standard.
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Materials an d Equipment lnspection
Abrasive m aterial shall be inspected t o ensure compliance wi th the
requirements of this Standard. (see clause 8.5.2)
Painting / coating materials shall be inspected t o ensure compliance wi th the
requirements of clause 7 0 and the specified p ainting schedules (Appendix 3
of
this Standard.
Equipment for blast cleaning and paint application shall be inspected to ensure
the com pl~an ce i t h the requirements
of
this Standard (see clauses
6.3,
8 .5 .3
and 9 .5 ) and paint m anufacturer s recommendations.
lnspe ctionrres ting Equipment
The contractor shall heve the necessary equipment and tools for inspection
and testing of environm ental conditions, surface preparation and
painted. coated surfaces. All this equipment shall be approved by KOC prior to
starting any wo rk. The contractor shall provide calibration certificates for all
measurement and test equipment fo r KOC s revie w.
Environm ental Conditions Te sting
Prior to com men cing any blast cleaning paint application work, ambient
temperature, m etal surface temperature and relative hu mid ity
RH)
shall be
measured. Readings shall comp ly w it h clauses 8.2.1 and 9.4.1. For works in
confme d areas, the ox yge n deficiency and gas testing shall be performed.
Other environmental conditions, e .g , wind speed, wave tide and sandy or rainy
weather, shall be checked before the comm encement of any w ork.
Blasted Surface InspectionRest ing
Visual lnspection
a
Me tal substrate shall
be
checked t o ensure spatter
/
protrusions removal,
cleanliness e tc. prior t o blas t cleaning.
b
Blast cleaned surfaces shall be visually inspected (surface mag nifier m ay
be used) t o ensure the absence of al l types of imperfect ions and
contam inants and for the conformance w ith the specified visual standard
mentioned in th e paint ing / coating schedules (Appendix 3).
Surface Profile Testing
O n dr y blast cleaned surfaces the prof ile he igh t shal l b e spot checked
y
means o f surface profile comp arator or y replica tape and a calibrated
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micrometer in accordance w ith ASTM D44 7 or NACE RP0287 o ensure the
compl~ancewi th p a m n g schedule requirements.
Contammants Free Testing
W hen requested b y KOC, a Potassium Ferrocyanide paper test shall be carried
out t o con firm the absence of contamination of the blast cleaned surface by
soluble iron salts. This shall be done in accordance w it h
BS 5493
Appendix
G
Painted Surface lnspectionrresting
Visual Inspection
All painted surfaces shall be visually inspected t o ensure th e absence of skips,
overspray, sags, foreign panicles contamina tion, air poc kets, drips, holiaays
and
s y
other palnt defects. The repair of damage dldefected c oating shall be
d o n e In accordance wtlh clause 9 .8
of
this Standard.
Curing o f Inorganic Zinc Srlicate Primer Tes t
a ) Z ~ n csilicate primed substrate shall be tested for adequate curing prior to
0vercoa:ing (see clause 9.6.4). The test shall be perform ed as fol lows:-
Rub the applred c oating w it h a clean tissue or piece of cloth. There
should be no t race of paint on the cloth. The cloth should then be soaked
In cleaners
s
recommended b y the paint manufacturer; and again rubbed
on the coatrng. After about thirty seconds there should be no trace of
zinc on th e cloth. If the re is any greyness, the n th e zinc sil icate IS not
ully
cured and sh l l
not
be overcoated.
b The manufacturer s recommendations instruct ions shall be ful ly adhered
when performing this test .
Paint Fi lm Thickne ss Test
a
The paint shal l conform t o the system and t o the min im um film thickness
as specified
in
th e pa inting schedules.
b
he w e t ilm thickness
WTT
shall be spot measured as
an
initial
indicat ion of the expected dry
ilm
thickness
IDFT .
Th e measurement
shall be in accordance with
ASTM
D1212.
C)
The DFT of individual coats end
of the
tota l paint ing sys tem shall be
measured
in
accordance with
ASTM
D l 18 6 o r SSPC-PA2. There shall be
at least one area ea ch for horizontal, vertical and curv ed surfaces. For
internal paint ing in storage tanks, t he
film
thickness shall
be
measured at
te n (10 ) random ly selected areas.
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l
A minimum of f ive
5 )
readings shall be taken in each area. Additional
readings shall be taken , if there is any change in personnel, application
equipment, spray nozzle size, thinning of the paint, etc.
e) The (DFT) shall be measured by using an approved coating thickness
gauge suitable for the given type of painting system and thickness range.
f )
The gauae shall be calibrated prior any measurem ent. The
calibration
shall be repeated at least once an hour if work ing on the same surface,
and before measuring fi lm thickness on th e insides of angles and at
points nearer than
5
m m from an edge.
Paint Adhesion
When requested by KOC, a spot adhesion tes t may be carried out using a
suitable Adhesion Tester. The paint adhesion recorded mu st be at least eqilal
t o the specifled adhesion b y the paint manufacturer fo r th e typ e of paint
and or sys tem .
The paint adhesion testing shall be in accordance wlth ASTM
D3359 or ASTM D4541.
Hohday Detection (Porosity Check)
All coated me tal surfaces shall be subjected t o visual inspec tion for holidays,
pinholes and overspray. For special coatings where pinholes cannot be
allov,~ed, a ful l scan holiday test shall be done, using suitable equipment for
each typ e of coating as high voltage can cause damage t o coatings. The
acceptable level of pinholes shall be subjected t o KOC 's approval. Holiday
detection test shall be carried out in accordance with
NACE RPO188
QU LITY ASSURANCE
The Contractor / Manufacturer shall operate quality system s to ensure that the
requirements of this Standard are achieved. The quality system s shall be
preferably based o n IS 9000 series of standards and the contractor
manufacturer shall demonstrate compliance b y providing a copy of the
accredited certificate or th e quality manual. Verification of
a
contractor's
manufacturer's quality system is normally part of th e pre-qualification
procedure and is, therefore, no t detailed in th e core te xt of th is Standard.
DOCUMENTATION
General
All correspondence, drawings, instructions, data sheets, design calculations, or
any other written information shall be in English language. I n case of dual
languages, one language shall be English.
All dimensions, units
of
measurement, physical constants, etc. shall be in
SI
units, unless otherw ise specified.
All docu me nts (texts, spec ifimtions, data sheets, etc.) shall e provided with
electronic files in the approved software MSWord, Excel, AutoCAD, etc.).
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A n y design calculations shall be submitted
in
the approved and widely
used
software agreed
by KOC.
Work
Proposal
The
contractor shall submit his proposal for all aspects of
work, for the
approval of
KOC
prlor t o th e com mencement of any w ork. This will include
t h e
following:
a) Information on work location, materials selection, equipment to be u se d,
items t o be coated, surface preparation, painting schedule to be used,
etc.
b
Manufacturer's technical data she et, material performance ce ni fc at es
and te st a pprovals shall b e provided for ea ch paint coating product.
C
f d ~ t e r ~ a iafety dsta she ets and safety precautions to be taken
d
lnspect~on
n d tes;
plans and procedures, and the equipment to be u sed.
e
S p e c ~ f c epair proposals t o satisfy the requirements of clause
9.8
for
both extensive and minor repair.
Work Records~Reports
The cont ractor shall operate a comprehensive recording reponing sy st em on all
ss pe ct s of th e painting work includmg inspection/testing work. The dat a shall
be se t out on painting work reco rdlda ta sh ee t within 24 hours of carrying out
a
sp ec ~f ic ork. Appendrx
1
shows
a
sample of this recordjdata s he et .
Final
Report
A report shall be s u b m ~ n e don completion
o
th e painting works. The fmal
repon shall include a summary on all aspects covered e.g . , surface
preparation, painting s ys te ms u sed and inspection and testing records
performed.
PAlNTlNGlCOATlNG SCHEDULES
The
painting coating sche dule s
A-E)
are a t tached to
t h i s
Standard in
Appendix 3 T he requirements f or su rfac e preparation an d paintinglcoating
systems are listed for categories
of
onshore offshore structure, equipment
and other facilities.
The paintinglcoaring sch edu les explained
in
Appendix
3
are:
Schedule A External PaintingICoating Sy st em s for Onshore Storage
Processing Equipment.
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Schedule Painting System s for Onshore Structura l Steel wo rks .
Schedule C Painting Systems for Mec hanical, Electrical and Instrumentation
Equipment
.-
Schedule D ?ainting.lCoating Systems for Offshore Structure and
Equipment.
chedule
E
Internal Painting System s fo r Storage and Processing
Equipment.
14 0
OLOUR S HEDULE
The f in ishing colours t o be applied t o various equipm ent and faci li ties
sh ll
be
n
accordance wirh colours mentioned in colour schedule
of
Append~x
.
S~ e::~ng
di f fe rent
co lmrs
is
subject to KOC's approval.
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7 5 0 APPENDIX
PAINTING RECORD DATA SHEET
........
roposed by
.................
......
Checked by Date: .
...........................................
tem being painted. ............... ....................Location.
Substrate Material. .
........................................................................
A. Surfact Preparation
.......................
urface Cleanliness
(Visual Standard i
Surface Condition
.......................
S;* ~:E Prc li~
He ;?
. . . . . . . . . . . . . . . . . . . . . . .
cf,:,c:c-l
Ambient Temperature ( 'C)
. . . . . . . . . . . . . . . . . . . . . . .
C o v a m ~ n a n t s ree T e s t
. . . . . . . . . . . . . . . . . . . . . . .
.......................
e.0.
Point
( T I
.......................
~ i i i d € umidity C/o)
SLI:~B:E Temperature ( 'C)
.......................
Cleaning Method(s)
.....................
......................
brasive type
Abrasive S ~ e v e ~ t e .....................
B. Paint
Application Equipment
Primer 2 n d Coat 3rd Coat 4t h Coat
Brush Roller /Con. Sp ra y' A~ rle ss
.............................. ..............................
Conventiona Gun
....................................................................
A~r l es s IP S z e Angle ( thou'deg'
....................................
Pump Ratio
................._.........................,,.......................
....................................................................
upply
Air
Pressure (psi)
C. Painting Con ditions
Relative Humidity
( I
Surface Te mpe rature t°Cl
Ambient Temperature PC
Dew P oin t ( " a
....................................................................
ther weather Condit ions
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P INTING
RECORD
/
DATA SHEET
Contd...
0 Paint Coating Materials
...............................anufacturer
TypeXode Bstch No. Product No No of
t o m
Cur~ng er~od
Primer ............. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .
Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finish
. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .
Colour Codmg
Over Coa?~ng
T ~ m e
nterval ......................................................................
T o ~ a l V ......................................................................
To?al
D R
......................................................................
Adhesion Test ......................................................................
P~nhole est
......................................................................
Material Safety
Data
Sheet
(
for
information
DOC. NO KOC P 001
Remarks
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APPENDIX
A
.
OLOUR SCHEDULE table
1
Item
Stora
e
8
Processing Equipment:
&Pressure Vessels, Exchangers, Heaters
Columns, Skirts, Saddles and Piping
Rotating Equipment
ElectricallMechanicaI Equipment
Instrumentation Equipment
Control Panels/Equipment Support
Pipe
Works, Valves and Fittings
All valves/devices used for over pressure
protection e.g., Safety valves).
Overhead Travelling Crane
Structural Steel Works
Hazards Firelsafety systems
Gas Cylinders (Industrial)
Gas Cylinders
(Medical)
Safety Signs
Grey
Refer to Table
2
KOC-P-017
Blue
Yellow red
Aluminium
Rritish
Standard
No.
-....
- P
S
4800
Remarks
Alirminium colour shall
be
Non
Leafing grade.
BS
381 C
Ref.
No.
107
BS 4800
Shade
08-E-51
BS 4800
Refer to KOC-P-017 for colour
coding arrangement and
application for piping.
Refer to
Table
2
BS 381
Refer to
Table 3
DS 349
Refer to Table 4
RS 1 3 1 9
Refer to
BS 5378 RS 5378
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. -
[DOC
NO. KOC P 001 1
Page 38 of I REV. 2
APPENDIX 2C
cOLOUR IDENTIFICATION OF G AS CYLINDERS FOR INDUSTRIAL GAS VIDE
BS 349
Table3 Contd...)
Methyl Ctrlotrde C H L I
Neon
Ne
N~tro~en
. .
N
Oxygen
- . .
r
Phosyerre I -
ropane Comrnerc l l
- - .
-.
Sulphur
0:oxldtt
SO
Cheen
~gnal
ed
- - - *
b ~ h t runsw~ck
GIeen
41
1 Black
I - bss
630 a k
.
Gbss
None
.
P ~ L O C ~ ue 103
Note
For
dour+
White
and E I k k u)reference number is
quoted
inBS 381C.
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IEV.
APPENDIX
COLOUR IWNflFlC TION
FOR MEDICAL
GAS-VlD+RS
1319
Table 4
Vl)ua
End
Oxvaen
I
0 2
Nitrous Oxide
_.
N70
Cyctopropm
.
C3Hn
arbon Dioxide C02
Ethylene
C7H4
Helium
He
Nitroaen NZ
Oxygen Carbon Dioxide (mixtures) 0 7 C07
Oxygen
nd
Helium M i m e s
0 2
He
Air Media l )
AIR
Oxygen ndNitrous Oxide mixlures 0 2 N 7 0
W h l t ~
French nlue
-
-
ig ht Orange
-~r en ch rey
Dark Violet
-
~ddle rown
--
R i x
--
White and
BS
381C
I ...
Illack Gloss
-
166rnnch Rlue GlossIMatt
~
.1ghtOrange
7
GlosslMatt
rrench Grey
-
630
Gloss
Dark Violet 796 Gloss
Middle Drown 41 1 Gloss
French Grey
-- -
63 Gloss
Black Gloss
Rlack
I
Gloss
French Grey
.
63 Gloss
.
French
Wue 166
Gloss
French Rlue
I
166
I
I
I
NOTE
For
White
and
81ack.
no referencenumber
k quoted in
BS
381C.
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OOC
NO. KOC P 002
I
Page 45
of
55
I Rev 2
. -
APPENDIX
--8
SCHEDULE : PAlNTlNG SYSTEMS FOR ONSHORE
TRUCTURAL- - . TEEL WORKS
I 1
G, Q.
Lbddcn
Nmdrdl.
Fmclng, Stdrwavs. Wdkwnv
Stdr
t reads, Cable trays, Du ctinn rmd Platforms.
2 ~encrd oncrete I ot Concrete Encased Structrmd Steel Work.
SCOPE
Ladders. platforms.
handrails, sta ir treads.
open
grid flooring sted
grating.
SPECIFICATION
Hot dtr, galvantnnq anti Top
cnattnq
Hot
dip
galvani~ing
Plqarat
on
- Vtwal standard Sa
2
BS 729 rr,qrrtr~rncnts
Coating-
Hot dtp ~alvan17c hall
b~
car r t4
OII~
In accordancr, wvth RS 729
The mtntmum coattnq wo qht
shall be 610 ~rarnslrn' urface
Top coating
Top coatvnq of galva nrwd
surface maybe rrq r~ t r dor
colour c d mg
r
for rnaintmanc~
of smrral weathered tt m s
&qal;rtio
In accordance wi th clarrse
8.12
of this Standard.
Interm(H1~ale
Two-pack High-build Epoxy
FAjsk
Recoatable Acrylic Polyurathane
in
the reqtrirmf colorrr.
REMARKS
Wh~rc?ot galvanlsed. rnc system 'R2' for all
axccpt handrails which shall be A 1
1.
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SCHEDULE
C: PAINTING
SYSTEMS FOR
MECHANICAL
.
LECTRICAL
- - ND
NSTRUMENTAllON QUIPMENT
Item: RotatingEqulpmcnt lhmps,
Compressors. Motors. etc.), Elr?ctrical Eq tt i pmn t m Equipment's
Supparts
SCOPE
Pumps, Compressors. Motors. Fans
etc.
- -
.-.- .. -- .
SPECIFICATION
MIN. THICKNESS
DFT IMICRONI
-
. - -
. .
- A s f o r A l - 1 , A l - 3 ,A1 4 a n d A l - Bsys t cm s
Machinery and drivms. instrrtrnents
Pi
ass ocia l4 valves may
he fin ish coated tn accordance wcth man~rIactttrc?r's taridard
coatinn syslmns.
Manttfactrtrcs shotrld provide d~tails
f
the p r o m s d
PAINTING
systems for fttttrre maintcmance and fopair.
The pa nt system mttst bc? capable of wtthstanding the
c?nvtronrncntal cnndt ttons for pcrrtod nf
5
vcnrs to Ri3 pm BS
3900 H scale of drylrw of ntstinq.
Movi
Parts:
FF~~SZ~ I TXP~~ouplings etc.
Electrical Equipment
Motors, Switchmars, Standard
quipment
ransformers
Rectifiers
Preprat on-
VI~II~Itandard Sa3
S ~ ~ r f a c orollle 25-35 micron
Coattng Syz1c.m-
Shail i)(?a ~or system A 1-1
This type of eq ~ripment hall be prc?pard, prim&
t
finished
in accordance with the man~tlact~rrcr 'standartl.
The system mttst
be
canahle of wtthstanding th e
environmcnfal cnncfitions for
period of 5
ycars to Ri3,
per
BS
3 9 0 0 H3 scale o f d q r w 01 rusttnq.
Housings and
Equipment Supports.
Pr9arjat;bni
~tsr~aTstandarda 2
Surlace proltle
25-35
micron
Pnmitnt :
coc rtch Epoxy
Intr?rrndiale:
' f w d
High
buitd
MI0
F w x v
Ftnrsh:
Ar.iviZ ModifidPolyurethane
Control Pands
As lor C3 Svstem
REMARKS
Total patnting system to be shop appl id.
Total painting system to be shoo applied
Manufacturer's standard shall be sttbiect to
KOC approval.
Housings to be finish coated in sdlers
works.
Shop fabricated supports shan he
patntcd in workshop.
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APPENDIX 3
NGtCOATING SYSTEMS FOR OFFSHORE STRUCTURE
8
EQUIPMENT
EXTERNALSUR_FACES ATMOSPHERIC
ZONE,
SPLASH
ZONE
AND SUBSEA
hems: Structural Steel Tanks. Vessels.
Piping,
Valves Plant Equipment.
Dl:
Atmospheric
Zone
Pn md surface
to
be
tree
of zinc
salts
prlw
to
1 coatrru.
Inorganrc Ztnc Srbcatepruned surfacesh ll
be
rested lor w r e e of cure pror
to
over
coarmq. SM clause 10.6.2)
Prtriwd surfaces to be f rw of
rm
salts prmr to
funsh coalmy.
Inorgmrc Zmc Sllrcate pr~nwd urface shall be
leslt?d oc dqru e of cure p r w to
ovw
coarmg.
l s w clausel0.6.2J
econd
ccktt to ba
ppked
as
a
trust prior to lull
Cwlrn().
S m o
s 01-1
Allerndi~ve lyruents to
Al shall
be used
m
zone
1
;vws lscw clause 6.5 .1 7.1
5).
Slllcorl Alu~nrwnl~nrslr oal
nwy
no1 tully cure
ur l l~lqurpmcrbl In servce.
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APPENDIX
SCHEDULE O 1Contd..
S OPE
CS
ow alloy
s t d sttrfaces.
Uninsrrlated
Up to
55 °C
Stainless steels AlSl 300
and
400 series and duplex
t y m
Up to
120ec
---- Ad..
SPECIFICAT ON
Propara1nn:
~ l s ~ r n itindard Sa 3
S~rrfacc roltlc 50 nvcrons
First coat:
AI~Meini pray
Finlsh:
t;?mperatrrre
A l
Silicone
hcparatlo?
IT1stcai st ~r ~c fa rda
3
Prrrn~rig-
/6orclawc Zinc Silicate
Tle coat-
Two-pack Epoxy
Fincsh:
Two gack hiqh bttild MI 0 Epoxy
f2 coats1
Fqariyio":
Vlsr~a l tandard Sa 3
Srr rlxe profrle 5 0 micron
Prirningi
hi%<antc Zinc Sil icate
~intsh:
Twollack Epoxy tie coat
~ryara t ron :
V ~ w a itandard Sa 2
In
accordance wl th clattse
8 11
Prrmtng
li q11 I~celd poxy for stainless
stclcls
Ftnl5hl
Rrcoa tahlr Acrylic Polyr trclthanc
iO
70
Total 17 0
7
5
25
7x75
Total
250
75
25
Total
1
0 0
Total 700
REMARKS
ShRH not be
used
far services opetatkg
hr
wea
zone
1.
- Primcd srtrface to be f r w of 7inc salts prior to
f ncsh coatinn.
Inorqanrc Zinc Silicate primed swfacc? shall b e
t ~ d dor dcqrcv of cure prior to over
coating. l sce clartse
10.6.2
As above
Dl -5'
remarks.
Under
no
drcumlPtrnces
shall 7inc conlain inn paints
hr?
rt s 4 on starnl~ss lael s~trfaccs
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SCHEDULE
D
lcontd
I
CS
slruclures
and
Jelt~es.
Galva~wtnl tccl structure
Harldrall
Galva~~lredteel structure
Gra1111y
. . .
. .
SPECIFICATION
Pre@fmon.
Vtsual st~~rdard
a 2%
In accordawe w11lr clause 8 .11
1
I~US
Sldllddrd
Coatmc_l
Two
coals ol Foster Allas hual
reusidrlcu 57 73 r approvcd
F
I
Coal Tar
Epoxy 13
coals)
wN 7HICKNESS
OFT IMICRQNI
Same
as 0
7'
above
Galvarured
surlaces
must
be as
per
BS
729.
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APOENOIX 3
SCHEDULE Contd.1
Deck Heavy Duty Non -sl ~p
Deck
Light Duty Non-slip
Preparation;
- VISBI~I?aridardSa 2
St l r l ac~~r ~ l t l o
5
35 micron
Priming;
Ztnc r~ c h pack Epoxy
Finish:
-- .
S ~ k aand fill4m o d i f i d q m xy
ckd d ~ n g
overed
wtth non spark ng
aggregate,
sweep away ex c~ ss
SF ;
Two pack epoxy
P_rpa""
V~su al tandard Sa
2%
Surface profda 25-35micron
Priming:
zn:
r~ ch pack poxy
Finish:
Two pack Epoxy co ve r~
with
non-
sparking aggrcgalc?
5 0
Total 3100 3.1 mm)
50
250
Total 300
.
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DOC. NO. ROC-P-001
I
Page
5 of
--
--- -
.
REV.
2
APPENDlX
E
SCHEDULE
E:
lNTERNAL PAINTING S Y S W M S. OR TORAGE
A
AND
PROCESSING
- FOUlPMENT
It-:
Tanks k strlrJIB~~tlSlopIt)rmln.IBrbckish
ater. Desalter wash water and Fire water tanks. Wetldr y crude tm ks
nd
Test tmks.
Gmerdf f resh
wster
Services. SeparMors. Drains sump vessel. Drains flash vessel nd Desdters.
Wet crude storefln and Test
tanks (fixed or floating
roof) inclrrding int ma l
structures and piping inside
and or~tside.
I
Wet crude starm e snd Test
tanks (fixed or floating roof1
incldin l Interns1 structures
and piping inside and
outside.
IndustrisflBaflastl
SloplDemin. /Brackish
water, Desalter wash water
(md fire water tanks
(inckrdmg nternal
structures and piping inside
nd outside).
Dry crude tanks
f_opara Ion-
Vlzr~al tandard Sa 2
s~~rfacerof~lc
5
mtcron
Pr~m~_ng In_tfrmc.dtat~lFtn~sh:
fi;rw coats ol Coai f m Epoxy (Amme
cur~ d )
P'eparation:
Vt sr d SiSndard Sa 2
surface profile 7 5 mlcron.
Priming:
m m t d e Epoxy primer
Finish:
Twocoa ts o f high build Coal Tar Epoxy
Reparat oz
31CuXStandardSa 2
surface proftle
7 5
micron.
Rimingl~nyrmediateIF~nis~
-
oats
Cod
f i r
Ei)oxv IAmine
cured)
The
shell plates may be sr thwt to
coating as per systc?m
€2.
if rcquird
bv
KOC-MV-007,Data Sheet.
MIN. THICKNESS
or
T MICRON)
-
-
3x150
Total
4
50
Total 350
3x150
Total
F~hrc t ss ining
in
~ccnrdance ~t h
OC-P-
0 0 2 Part 2.
Entire floor plt~ s mcters of the loww shd l
corssc or mar. expw,ted water I e v ~ l
0.5
mc.tc.rs) whichcvcr is gredtcr.
Rdnr to KOC-MV-007 or information on
arms to he coated I ot coated bv coal tar
m x v .
Same as E 1 1 above.
Fibre glass lining in accordance with
KOC-P-
0 0 2 Part 2.
Entire floor plus 0.5 meters of the loww shell
course.
Fibre glass lining in accordmw w~th OC P-
002
Fnt~rc.loor plr~s
5
meters ol ttic 1owc.r shell
cot~rsc.
. . .
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ACKNOWLEDGEMENT
This S tandard has been approved
by
th e S tandards Technica l Commi t tee STC
consist ing of t he following
:-
,:. Ali ti
Babe
( Sta nda rds Div.)
Chairman
M I
ohd. Ernam
( Ins?.
Corr. Div.) De put y Chai rman
Mr. S. Kumar
(
Stan dard s Div.) Secretary1 Member
Dr. Moham mad l lyas
( Sta nda rds Div.) Memb er
Mr. Khalid S. AI-Ali (
Maint. Proj. Div.) Me mb er
Mr.
Henry
S,
Hill (
Maint. Ping. Div.) Mem be r
Mr. Jassem Al- Ouraini
( PMD-
North
)
Member
The dre9
c
thls Standard h a s been ci rculated t o the KOC User De pa nm en ts for thelr
rEvli . i*i E 1s
c c r n m e x s werE r rzeived f rom the fol lowing
:-
ENGIKEERING GROUP PROD. EXPORT OPERATIONS GROUP
Gen . Supdt . Engg. Services
Gen. Sup dt . Prod. Services
Gen .
S ~ p 3 t . roj.
M g m t
N W 1
Gen. Supdt . P rod. Opns
(
N&W
Gen .
S ~ i p d r .
roj
Mgmt ( S
) Gen . S u p d t . P ro d. O p n s
( S
MAJOR PROJECTS GROUP INDUSTR IAL
SERVICES
GROUP
Ge7
S,>31
Engg Projects
N&E 1
Gen. Sup dt . Ahmadi Services
MAINTENANCE GROUP
Gen. Supdt . Main t . Sv cs .
Gen. Supd t . Maint .
(
N W
)
LOSS PREVENTION GROUP
Gen. Supd t . Consv. Insp.
Gen . S u p d t . Fire S a f e t y
DWIDED
ZONE
GROUP
Su pd t. Proj. Engg. Facilities
Div.
his KOC Stand ard
for
Painting an d Coating of Meta l Sur fa ces - New Construct ion
has
b e e n a m e n d e d
by the Task
Force
( TF-PC101
) compris ing
of the
following
m e m b e r s
: